Tonneau cover system for a cargo box with side rail end plugs with external mounting extensions

ABSTRACT

A side rail can define an exterior and an interior channel. A coupling strip within the exterior channel of the side rail can be positioned to selectively engage with a coupling strip of the tonneau cover. An end cap can be positioned on an end of the side rail. The end cap having an end face can include an interior extension within the interior channel and an exterior tab extension within the exterior channel between the longitudinal raised side portions. A retaining fastener can extend through the exterior tab extension and can fix the end cap to the side rail without the retaining fastener passing through the second coupling strip. The exterior tab extension can limit longitudinal sliding movement of the second coupling strip within the exterior channel.

FIELD

The present disclosure relates to tonneau cover systems for covering acargo box, such as a pickup truck bed.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

A tonneau cover made of a flexible material can be used to cover the boxof a pickup truck or the like and to protect the contents thereof fromthe elements. Such a tonneau cover can be made of fabric, flexibleplastic, or other sheet material. The tonneau cover can be secured tometal side rails along on the lateral sides of the cover and box withcooperating fastening strips. Because pickup trucks typically are usedand stored outdoors, the fabric and the means of attachment of thefabric to the frame can be exposed to the elements which can includeheavy moisture and extreme heat and cold, as well as dust, mud, rocksand other materials transported in the box.

Such exposure to the elements can create problems for the cover andsupporting structure of the tonneau cover. Efforts to use releasable orselective coupling strips, such as hook and loop fasteners, forattaching the cover to the metal side rails tend to be subject toexposure to the elements and wear from repetitive use of convenient,selective attachment means under those conditions. Moreover, exposure toheat and cold can cause the tonneau cover to expand and contract, makingthe tonneau cover either loose or wrinkled in appearance, or making itdifficult to secure the tonneau cover in the closed position. Thus, somemovement between the various components of the tonneau cover system canbe desired.

Tonneau cover systems employing the foregoing releasable or selectivecoupling strips can also suffer from a problem associated with prematureengagement of the cooperating coupling elements attached to the frameand flexible cover, respectively. Premature engagement can occur in suchsystems as the user of the system unrolls the cover over the metal framesecured to the upper edges of the sides of a truck box or other open topcontainer. As a result, wrinkles may appear in the flexible covermaterial following closure of the cover system. To remove the wrinkles,the user can be required to manually detach the strips of hook andloop-bearing material after the cover is stretched taut and thenreattach them in a position that removes the wrinkles from the flexiblecover. Again, some movement between the various components of thetonneau cover system can be desired.

Allowing such tonneau cover system component relative movement canresult in forces that tend to push end caps off of the side rails. Forexample, a longitudinally sliding coupling strip can engage friction fitend cap during expansion and contraction, or tensioning of the tonneaucover, or otherwise. In contrast, attempts to positively retain the endcaps with fasteners can inhibit the desired sliding movement of thecoupling strip.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

In accordance with one aspect of the present disclosure, a tonneau coversystem for covering a cargo box can include a tonneau cover having afirst coupling strip extending substantially along a side thereof. Aside rail can be structured for mounting to and extending substantiallyalong a side of the cargo box. The side rail can define an exteriorchannel and an interior channel. The exterior channel can be definedbetween two opposing raised longitudinal side portions, with at leastone of the raised longitudinal side portions defining a longitudinalslot. A second coupling strip can be provided within the exteriorchannel of the side rail and can be positioned to selectively engagewith the first coupling strip. The second coupling strip can include alongitudinal side received within the longitudinal slot to slidablyretain the second coupling strip within the channel. An end cap can bepositioned on an end of the side rail. The end cap can include aninterior extension received in the interior channel. The end cap caninclude an exterior tab extension received within the exterior channelbetween the longitudinal raised side portions, and the exterior tabextension can have an end face within the exterior channel between theraised longitudinal side portions. A retaining fastener can extendthrough the exterior tab extension and can fix the end cap to the siderail without the retaining fastener passing through the second couplingstrip. The end face of the exterior tab extension can be positioned toengage an opposing end face of the second coupling strip within theexterior channel to positively limit longitudinal sliding movement ofthe second coupling strip within the exterior channel.

In accordance with another aspect of the present disclosure, tonneaucover system for covering a cargo box can include a tonneau cover havinga first coupling strip extending substantially along each opposinglateral side. Two extruded side rails can be provided, and each siderail can be mounted to and can extend substantially along an opposinglateral side of the cargo box. Each side rail can define an exteriorchannel and an interior channel, and each channel can extendsubstantially along an overall longitudinal length of the side rails.The exterior channel can be defined between two opposing raisedlongitudinal side portions, and the raised longitudinal side portionscan define opposing longitudinal slots. A second coupling strip can beprovided within the exterior channel of each side rail and can bepositioned to selectively engage with the first coupling strip. Thesecond coupling strip can include longitudinal sides received within theopposing longitudinal slots to slidably retain the second coupling stripwithin the channel. An end cap can be positioned on an end of each siderail. The end cap can include an interior extension received within theinterior channel, and the end cap can include an exterior tab extensionreceived within the exterior channel between the longitudinal raisedside portions. The exterior tab extension can have an end face withinthe exterior channel between the raised longitudinal side portions. Aretaining fastener can extend through the exterior tab extension and canfix the end cap to the side rail without the retaining fastener passingthrough the second coupling strip. The end face of the exterior tabextension can be positioned to engage an opposing end face of the secondcoupling strip within the exterior channel to positively limitlongitudinal sliding movement of the second coupling strip within theexterior channel.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of one exemplary embodiment of a tonneaucover system in accordance with the present disclosure with a tonneaucover deployed over the cargo box.

FIG. 2 is a perspective view similar to FIG. 1, but without the tonneaucover deployed over the cargo box to expose a simplified illustration ofthe side rails and related components of the exemplary tonneau coversystem of FIG. 1.

FIG. 3 is an enlarged fragmentary perspective view of an end portion ofthe side rail and related components of FIG. 2.

FIG. 4 is an enlarged exploded perspective view of the end portion ofthe side rail and related components of FIG. 3.

FIG. 5 is a cross-sectional view of the side rail and related componentstaken through the screw of FIG. 3.

FIG. 6. is a cross-sectional view of the side rail and relatedcomponents taken through a mid-point of the side rail of FIG. 3.

FIG. 7 is a cross-sectional view of the end cap and bumper member of thetonneau cover system FIG. 1.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

Referring to FIGS. 1-2, an exemplary embodiment of a tonneau coversystem 20 of the present disclosure for a pickup truck 16 isillustrated. Some embodiments can include a roll-up flexible tonneaucover 22 and side rails 24 that can be clamped or otherwise positionedalong sides of the cargo box 18 of the pickup truck 16. The tonneaucover 22 can have a front header 26 coupled along a front edge and arear header 28 coupled along a rear edge of the tonneau cover 22. Whenthe tonneau cover 22 is in a deployed position over the cargo box 18,each end of the front headers 26 can be coupled to an end portion of theside rails 24.

In some embodiments, each end of the rear header 28 can be selectivelycoupled to one of the side rails 24 via a bracket or latch mechanism 30.Likewise, each front header 26 can be selectively coupled to one of theside rails 24 via a bracket or latch mechanism 54. One or both of thefront and rear bracket mechanisms 54 and 30, respectively, canoptionally include a tension adjustment mechanism to provide propertension on the tonneau cover 22, when it is in a deployed condition withthe headers 26, 28 coupled to the side rails 24.

The tonneau cover 22 can include a pair of tonneau cover coupling strips32 with each coupling strip 32 extending along respective opposinglateral sides of the tonneau cover 22. The side rails 24 can includeside rail coupling strips 34 that cooperate with the first couplingstrips 32 to couple the tonneau cover 22 to the side rail 24 alongopposing lateral sides of the tonneau cover 22. The side rails 24 can bemounted to and can extend substantially along the opposing lateral sidesof the cargo box 18. For example, clamping members (not shown) can beprovided to clamp the side rails 24 to the cargo box 18 using leg 25. Asanother non-limiting example, the side rails 24 can be screwed or boltedto the cargo box 18 using legs 25, or otherwise.

With additional reference to FIGS. 3-7, each side rail 24 can define anexterior channel 36. For example, the exterior channel 36 can be definedbetween two opposing raised longitudinal side portions 40. In someembodiments, the opposing raised longitudinal side portions 40 caninclude undercuts or can otherwise define opposing longitudinal slots42.

The side rail coupling strip 34 can be mounted within the exteriorchannel 36 of the side rail. For example, the side rail coupling strips34 can include longitudinal sides 44 that are received within theopposing longitudinal slots 42 to retain the side rail coupling strip 34within the exterior channel 36. Thus, the side rail coupling strip 34can be coupled to the side rail 24 such that it is slidable within theexterior channel 36 along a main longitudinal axis 37 thereof. This canfacilitate avoiding wrinkles when the tonneau cover 22 is unrolled toits deployed position over the cargo box 18 and tensioned as both thefront and rear headers 26 and 28, respectively, are coupled to the siderails 24.

In some embodiments, the active coupling elements 46 of the side railcoupling strip 34 can be provided at an upper central portion thereof.In some cases, the active coupling elements 46 are not provided alongthe longitudinal sides of the side rail coupling strip 34 that arereceived within the opposing slots 42 of the side portions 40. In someembodiments, the active coupling elements 46 can be hook or loopelements of a hook and loop fastener system. In some cases, the siderail coupling strips 34 can be a one-piece component. In other cases,the active coupling elements 46 can be formed as a separate componentthat is integrated with a separate base component that can include thelongitudinal sides 44 of the side rail coupling strip 34 that can bereceived within the opposing slots 42 of the raised portions 40.

The side rails 24 can additionally define an interior channel 38. Insome embodiments, the side rails 24 are each a single piece extrudedmember. For example, the side rails 24 can each be an extruded metal,such as aluminum, member. In some embodiments, the exterior channel 36,the interior channel 38, or both, extend substantially along an overalllongitudinal length of each side rail. The cross-section of the siderail 24 can, in some cases, remain substantially uniform along theoverall longitudinal length of the side rail 24.

An end cap 48 can be positioned on one or both longitudinal ends of eachof the side rails 24. The end caps 48 can include an interior extension50 and an exterior tab extension 56. In some embodiments, the end caps48 can include a slot 60 between the interior extension 50 and anexterior tab extension 56 that can receive a wall 62 of the side rail24.

The end caps 48 can include an interior extension 50 that can bereceived and retained within the interior channel 38. The interiorextension 50 of the end cap 48 can have a plurality of sides 52. In someembodiments, each of the plurality of sides 52 can at least partiallycontact an adjacent side of the interior channel 38 of the side rail 24.

The end caps 48 can additionally include an exterior tab extension 56.The exterior tab extension 56 can be received within the exteriorchannel 36 between the longitudinal raised side portions 40. Theexterior tab extension 56 can have an end face 58 that can be at leastpartially received or positioned within the exterior channel 36 betweenthe raised longitudinal side portions 40. The end face 58 of theexterior tab extension 56 can engage an opposing or adjacent end face 35of the side rail coupling strip 34 within the exterior channel 36 topositively limit longitudinal sliding movement of the side rail couplingstrip 34 within the exterior channel 36.

In some embodiments, the exterior tab extension 56 of the end caps 48can have a recessed portion 64 in an exterior face or surface 66 that isadjacent the end face 58. The recessed portion 64 can include apreformed central through-hole, through which a retaining fastener 68can extend. The preformed through-hole of the recessed portion 64 canact as a pilot for the fastener 68, which can facilitate correctlocation of the fastener 68 during manufacturing. In some embodiments,the fastener 68 can include a head that can be received within therecessed portion 64 so that at least a portion of the head of theretaining fastener 68 is recessed relative to the exterior face 66 ofthe exterior tab extension 56.

In some embodiments, the retaining fastener 68 can extend through theexterior tab extension 56 and through the separating wall 62 of the siderail 24 positioned within the slot 60 between the exterior tab extension56 and the interior extension 50 and into or through the interiorextension 50. Thus, a single fastener can fix both the interiorextension 50 and the exterior tab extension 56 to the side rail 24. Thiscan facilitate initial manufacturing and any subsequent removal orreplacement of the end cap 48. The end cap 48 can also be formed ormolded as a single piece element, without the need for costly machining.

As illustrated, the retaining fastener 68 does not extend or passthrough the side rail coupling strip 34. Thus, there is no need for theside rail coupling strips 34 to include weakened areas, which might leadto premature failure thereof. Similarly, there is no need for additionalmanufacturing steps to form slots in the side rail coupling strips 34 toallow passage of the fastener 68 therethrough. In some cases, theretaining fastener 68 can be a threaded fastener, such as a screw.

The retaining fastener 68 can securely couple the end cap 48 to the siderail 24. Thus, the retaining fastener 68 can help resist forces thatwould tend to separate the end cap 48 from the side rail 24. Forexample, such forces on the end face 58 of the exterior tab extension 56can result from engagement of an adjacent or opposing end face 35 of theside rail coupling strip 34 that positively limits longitudinal slidingmovement of the side rail coupling strip 34 within the exterior channel36.

In some embodiments, an end cap 48 is provided on both ends of the siderail 24, the side rail coupling strip 34 can have an overalllongitudinal length that is less than a longitudinal distance betweenthe end faces 58 of the end caps 48 mounted on the side rail 24. Thus,the side rail coupling strip 34 can slide longitudinally within theexterior channel 36, until the end face 35 of the side rail couplingstrip 34 engages the opposing or adjacent end face 58 of one of the endcaps 48. Because the side rail coupling strip 34 is allowed to slide,forces on the strip 34 that might otherwise damage the side railcoupling strip 34 during coupling and uncoupling with the cover couplingstrips 32 are reduced. This limited sliding action can also be providedwithout the need for a slot in the strip 34 to receive a stop, whichslot would create a weakened area that might lead to premature failureof the side rail coupling strip 34.

In some embodiments, the end cap 48 can include a protective or flexiblebumper 70 at a distal end 78 thereof. As one example, the distal end 78of the end cap 48 can include raised end cap side portions 76 thatdefine opposing bumper mounting slots 74 and a channel 80 between theraised end cap side portions 76. The protective bumper 70 can be coupledto the end cap 48 via a mounting extension 82 including flanges 72 thatcan be received within the opposing slots 74.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc., may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

What is claimed is:
 1. A tonneau cover system for covering a cargo boxcomprising: a tonneau cover having a first coupling strip extendingsubstantially along a side thereof; a side rail structured for mountingto and extending substantially along a side of the cargo box, the siderail defining an exterior channel and an interior channel, the exteriorchannel being defined between two opposing raised longitudinal sideportions, and at least one of the raised longitudinal side portionsdefining a longitudinal slot; a second coupling strip within theexterior channel of the side rail and positioned to selectively engagewith the first coupling strip, the second coupling strip including alongitudinal side received within the longitudinal slot to slidablyretain the second coupling strip within the channel; an end cappositioned on an end of the side rail, the end cap including an interiorextension received in the interior channel, and the end cap including anexterior tab extension received within the exterior channel between thelongitudinal raised side portions, and having an end face within theexterior channel between the raised longitudinal side portions; aretaining fastener extending through the exterior tab extension andfixing the end cap to the side rail without the retaining fastenerpassing through the second coupling strip; wherein the end face of theexterior tab extension is positioned to engage an opposing end face ofthe second coupling strip within the exterior channel to limitlongitudinal sliding movement of the second coupling strip within theexterior channel.
 2. The tonneau cover system according to claim 1,wherein each of the two opposing raised longitudinal side portionsdefine a longitudinal slot, and wherein the second coupling stripincludes two longitudinal sides, each longitudinal side being receivedwithin the longitudinal slots, respectively, to retain the secondcoupling strip within the channel and exposing a central active couplingelement.
 3. The tonneau cover system according to claim 1, wherein thefirst and second coupling strips comprise hook and loop fasteners. 4.The tonneau cover system according to claim 1, wherein the secondcoupling strip is slidable within the exterior channel along a mainlongitudinal axis of the exterior channel.
 5. The tonneau cover systemaccording to claim 1, wherein the exterior tab extension of the end caphas a preformed hole therethrough for receiving the retaining fastener,said preformed hole including a recessed portion in an exterior faceadjacent the end face to receive a head of the retaining fastener. 6.The tonneau cover system according to claim 1, wherein the retainingfastener is a threaded screw.
 7. The tonneau cover system according toclaim 1, wherein the end cap comprises two end caps, each positioned onrespective opposing ends of the side rail, and wherein the secondcoupling strip has a length that is less than a distance between the endfaces of the end caps.
 8. The tonneau cover system according to claim 1,wherein the side rail comprises two side rails, each of the two siderails being structured for mounting to and extending substantially alonga respective opposing lateral side of the cargo box, and wherein thefirst coupling strip comprises two first coupling strips, each of thetwo first coupling strips being structured for extending substantiallyalong a respective opposing lateral side of the tonneau cover.
 9. Thetonneau cover system according to claim 1, wherein the end cap comprisesa bumper at a distal end of the end cap, the distal end including raisedend cap side portions that define opposing bumper mounting slots and achannel therebetween, the bumper being coupled to the end cap viaflanges received within the opposing slots.
 10. The tonneau cover systemaccording to claim 1, wherein the side rail is an extruded metal member.11. The tonneau cover system according to claim 1, wherein the exteriorchannel and the interior channel of the side rail each extendingsubstantially along an overall longitudinal length of the side rail. 12.The tonneau cover system according to claim 1, wherein the interiorextension of the end cap has a plurality of sides, and each of theplurality of sides at least partially contacting an adjacent side of theinterior channel of the side rail.
 13. The tonneau cover systemaccording to claim 1, wherein the retaining fastener extends through theexterior tab extension and through the side rail between the exteriortab extension and the interior extension and into or through theinterior extension.
 14. A tonneau cover system for covering a cargo boxcomprising: a tonneau cover having a first coupling strip extendingsubstantially along each opposing lateral side; two extruded side rails,each side rail being mounted to and extending substantially along anopposing lateral side of the cargo box, each side rail defining anexterior channel and an interior channel each extending substantiallyalong an overall longitudinal length, the exterior channel being definedbetween two opposing raised longitudinal side portions, and the raisedlongitudinal side portions defining opposing longitudinal slots; asecond coupling strip within the exterior channel of each side rail andpositioned to selectively engage with the first coupling strip, thesecond coupling strip including longitudinal sides received within theopposing longitudinal slots to slidably retain the second coupling stripwithin the channel; an end cap positioned on an end of each side rail,the end cap including an interior extension received within the interiorchannel, and the end cap including an exterior tab extension receivedwithin the exterior channel between the longitudinal raised sideportions, the exterior tab extension having an end face within theexterior channel between the raised longitudinal side portions; aretaining fastener extending through the exterior tab extension andfixing the end cap to the side rail without the retaining fastenerpassing through the second coupling strip; wherein the end face of theexterior tab extension is positioned to engage an opposing end face ofthe second coupling strip within the exterior channel to limitlongitudinal sliding movement of the second coupling strip within theexterior channel.
 15. The tonneau cover system according to claim 14,wherein the exterior tab extension of the end cap has a preformed holetherethrough for receiving the retaining fastener, said preformed holeincluding a recessed portion in an exterior face adjacent the end faceto receive a head of the retaining fastener.
 16. The tonneau coversystem according to claim 14, wherein the retaining fastener is athreaded screw.
 17. The tonneau cover system according to claim 14,wherein the end cap comprises a plurality of end caps, each positionedon respective ends of each side rail, and wherein the second couplingstrip has a length that is less than a distance between the end faces ofthe end caps.
 18. The tonneau cover system according to claim 17,wherein the second coupling strip is slidable within the exteriorchannel along a main longitudinal axis of the exterior channel betweenthe end faces of a pair of the plurality of end caps.
 19. The tonneaucover system according to claim 14, wherein the first and secondcoupling strips comprise hook and loop fasteners.
 20. The tonneau coversystem according to claim 14, wherein the retaining fastener extendsthrough the exterior tab extension and through the side rail between theexterior tab extension and the interior extension and into or throughthe interior extension.
 21. The tonneau cover system according to claim14, wherein the end cap comprises a bumper at a distal end of the endcap, the distal end including raised end cap side portions that defineopposing bumper mounting slots and a channel therebetween, the bumperbeing coupled to the end cap via flanges received within the opposingslots.